Footwear articles and methods of forming the same

ABSTRACT

Footwear articles are fabricated with materials and includes a structure that enable the articles to be non-toxic, natural, biodegradable, and/or environmentally-friendly. The structure of the footwear articles is configured for a user&#39;s foot, including aspects which allow for precision rigidity or flexibility within the footwear article. The footwear articles are capable of including cycling footwear articles. The cycling footwear articles are further capable of including aspects which provide enough rigidity to couple to clipless pedal systems on a bicycle, and other aspects which allow for a flexibility when walking. Methods of forming the footwear articles and related packaging systems are provided, which also utilize non-toxic, natural, biodegradable, and/or environmentally-friendly materials.

REFERENCE TO RELATED APPLICATIONS

This U.S. Non-Provisional Patent Application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 63/213,565, filed Jun. 22, 2021, and U.S. Provisional Patent Application Ser. No. 63/192,428, filed May 24, 2021, the entire disclosures of which are hereby incorporated by reference.

FIELD

The present disclosure relates generally to footwear. More specifically, embodiments of the present disclosure relate to shoes including cycling shoes. Footwear articles with various structures are provided herein. Articles and features for footwear are provided herein to increase structural integrity of at least certain portions of footwear and to enable the use and provision of various materials for construction of the articles.

BACKGROUND

The earliest known footwear articles are believed to date back to 7,000 or 8,000 B.C. Over millennia, various improvements to shoes and footwear articles have been developed. Shoes and footwear have been refined for various specialized applications including, for example, cycling. While conventional flat bicycle pedals may accommodate various different types of footwear, “clipless” pedals generally require a particular type of shoe that includes a cleat for interfacing with a pedal, as well as various features for obtaining stiffness and increasing handling and power transfer from a rider to a bicycle. An example of an existing cycling shoe is shown and described in U.S. Pat. No. 5,406,723 to Okajima which is hereby incorporated by reference in its entirety.

In addition to overall comfort and support, stiffness is often a critical consideration in cycling shoes. Cycling shoes provide a primary touch point between a user and a bicycle and provide an interface and power transmission point between the rider and machine. Generally speaking, stiffer shoes provide a better connection with a machine, minimize power transmission losses, and improve overall speed and handling. Cycling shoe systems of the prior art, however, generally rely on material selection to increase stiffness. Many cycling shoes are now known to incorporate carbon-fiber into the sole and other areas to increase stiffness and decrease weight. Various plastics, hydro-carbon derived materials, and other toxic or non-biodegradable materials may be provided in certain areas of known cycling footwear articles. These materials are generally selected in the interest of maximizing stiffness or strength while reducing weight and cost, and with little regard for environmental impacts.

SUMMARY

Accordingly, there has been a long-felt but unmet need to provide footwear articles including non-toxic, natural, environmentally friendly, and/or biodegradable materials, and preferably compostable (at least through commercial composting facilities), and wherein the articles include desired or required structural features. In some embodiments, cycling shoes are provided including a particular structure that enables sufficient structural integrity even when fabricated from plant-based and/or biodegradable materials. The present disclosure provides for methods, systems, and devices for footwear articles.

In one embodiment, a footwear article is provided that includes a footwear upper including a knit fabric, a heel counter, a footbed, and a lasting board, wherein at least one of the heel counter and the lasting board includes a plurality of stacked wood layers and wherein at least two adjacent wood layers include non-parallel grain directions.

It is an object of the present disclosure to provide footwear systems that reduce environmental impacts while still achieving the required strength and stiffness for cycling shoes. In some embodiments, systems are provided wherein footwear articles and all associated packaging includes non-toxic, natural, biodegradable, and/or environmentally-friendly materials, and preferably compostable (at least through commercial composting facilities) materials.

In some embodiments, footwear articles are provided that provide a combination of stiffness and support suitable for cycling while also providing flexibility and flexure to facilitate various off-bike activities including but not limited to walking. For example, a lasting board of the footwear articles are contemplated as including areas capable of interfacing with cleats for a clipless pedal system. By way of another example, the lasting board of the footwear articles are contemplated as including varying thicknesses caused by an increased or reduced number of layers throughout a lasting board of the footwear articles. In other embodiments, the lasting board of the footwear articles comprises one or more notches for increased flexibility.

In one particular embodiment, a footwear articles comprises a lasting board, a heel counter, and a footwear upper. The heel counter is configured to couple to the lasting board by inserting a portion of the heel counter into the lasting board. The footwear upper comprises a knit fabric, and is configured to couple to at least one of the heel counter and the lasting board. At least one of the heel counter and the lasting board comprises a plurality of stacked wood layers. At least two adjacent wood layers comprises non-parallel grain directions.

In some embodiments, at least one metal or fabric layer is inserted between adjacent wood layers of the plurality of stacked wood layers. In some embodiments, at least one of the heel counter and the lasting board comprises at least one fabric layer surrounding the plurality of stacked wood layers.

In some embodiments, at least an inner portion of the lasting board includes a support positioned in a toe region. In additional embodiments, the lasting board includes a void positioned proximate to the support in the toe region. In additional embodiments, the lasting board includes at least one location where a first subset of the plurality of stacked wood layers is differently dimensioned from a second subset of the plurality of stacked wood layers. A thickness of the lasting board is decreased and a flexibility of the lasting board is increased at the location due to the different dimensioning. In additional embodiments, the first subset of the plurality of stacked wood layers are dimensioned to include the support positioned in the toe region. The second subset of the plurality of stacked wood layers is differently dimensioned and does not include the support positioned in the toe region.

In some embodiments, the lasting board includes at least one notch positioned proximate to a toe region. The notch increases flexibility of the lasting board proximate to the toe region. In some embodiments, the footwear upper, the heel counter, the footbed, and the lasting board of the footwear article is biodegradable and compostable.

In some embodiments, the article comprises at least one aperture for a cycling cleat. In additional embodiments, the at least one aperture is a female threaded aperture for receiving a fastener for the cycling cleat. In additional embodiments, the at least one aperture includes one or more slots for receiving the cycling cleat or cleat hardware configured to couple to the cycling cleat.

In another particular embodiment, a method of forming a footwear article includes, but is not limited to, forming a footwear upper of the footwear article from a knit fabric, forming at least one of a heel counter and a lasting board for the footwear article from a plurality of stacked wood layers by laminating the plurality of stacked wood layers, where at least two adjacent wood layers comprise non-parallel grain directions, coupling the heel counter and the lasting board by inserting a portion of the heel counter into the lasting board, and coupling the footwear upper to at least one of the heel counter and the lasting board.

In some embodiments, the footwear upper, the heel counter, and the lasting board are each formed from one or more of a bamboo fiber, coffee bean fiber, soybean fiber, aloe vera fiber, corn fiber, cotton, silk, wool, recycled yarn, lyocell fiber, lyocell fiber blended with wool or recycled yarn, tea polyphenol fibers, chitin fiber, fibroin fiber, hemp fiber, cork, knitted fabric, wood, wood core, wood veneer, elemental or pure metal, and an alloy metal. In some embodiments, applying printing to at least one of the footwear upper, the heel counter, and the lasting board include printing, wherein the printing is applied using one or more of a soy-based ink, milk-based paint, laser etching, branding, embossing, and foil transfer.

In another particular embodiment, a system including a footwear article comprises a set of footwear articles, a foot form device configured to fit within each footwear article of the set of footwear articles, and packaging including paper capable of wrapping around the set of footwear articles. Each footwear article comprising a lasting board, a heel counter, and a footwear upper. The heel counter is configured to couple to the lasting board by inserting a portion of the heel counter into the lasting board. The footwear upper comprises a knit fabric, and is configured to couple to at least one of the heel counter and the lasting board. At least one of the heel counter and the lasting board comprises a plurality of stacked wood layers and wherein at least two adjacent wood layers comprise non-parallel grain directions.

In some embodiments, the packaging and the foot form device are each fabricated from one or more of pulp, recycled paper, recycled paper with plant seeds, and wherein at least one of the packaging and the foot form device includes printing applied using one or more of a soy-based ink, milk-based paint, laser etching, branding, embossing, and foil transfer. In some embodiments, the foot form device includes a cleat-fitting and alignment device for installing a cycling cleat on a second footwear article of a second set of footwear articles by marking a cleat position from a footwear article of the set of footwear articles on the cleat-fitting and alignment device as a template. In some embodiments, the packaging comprises a cleat measurement tool for installing a cycling cleat on a second footwear article of a second set of footwear articles by marking a cleat position from a footwear article of the set of footwear articles on the cleat measurement tool as a template.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The transitional term “comprising” is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, ratios, ranges, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about” or “approximately.” Accordingly, unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, ratios, ranges, and so forth used in the specification and claims may be increased or decreased by approximately 5% to achieve satisfactory results. Additionally, where the meaning of the terms “about” or “approximately” as used herein would not otherwise be apparent to one of ordinary skill in the art, the terms “about” and “approximately” should be interpreted as meaning within plus or minus 5% of the stated value.

All ranges described herein may be reduced to any sub-range or portion of the range, or to any value within the range without deviating from the invention. For example, the range “5 to 55” includes, but is not limited to, the sub-ranges “5 to 20” as well as “17 to 54.”

The transitional phrase “consisting of” excludes any element, step, or ingredient not specified in the claim, but does not exclude additional components or steps that are unrelated to the disclosure such as impurities ordinarily associated therewith.

The transitional phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

The preceding is a simplified summary of the disclosure intended to provide an understanding of some aspects of the settler devices of this disclosure. This Summary is neither an extensive nor exhaustive overview of the invention and its various aspects, embodiments, and configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below. As will be appreciated, other embodiments are possible using, alone or in combination, one or more of the features set forth above or described herein. For example, it is contemplated that various features and devices shown and/or described with respect to one embodiment may be combined with or substituted for features or devices of other embodiments regardless of whether or not such a combination or substitution is specifically shown or described herein. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.

Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure and is not meant to limit the inventive concepts disclosed herein.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein.

FIG. 1A is a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 1B is a side elevation view of a component of a footwear article according to the embodiments of FIG. 1A.

FIG. 2 is an exploded view and an illustration of an assembly step of a component of a footwear article according to embodiments of the present disclosure.

FIG. 3A is a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 3B is a side elevation view of a component of a footwear article according to the embodiments of FIG. 3A.

FIG. 4A is a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 4B is a side elevation view of a component of a footwear article according to the embodiments of FIG. 4A.

FIG. 5A is an exploded view of a component and related assembly method of a portion of a footwear article according to embodiments of the present disclosure.

FIG. 5B is a cross-sectional elevation view of a component formed from the assembly method according to the embodiments of FIG. 5A.

FIG. 5C is an exploded view of a component and related assembly method of a portion of a footwear article according to embodiments of the present disclosure.

FIG. 5D is a cross-sectional elevation view of a component formed from the assembly method according to the embodiments of FIG. 5C.

FIG. 6A is an exploded perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 6B is a side elevation view of the component of a footwear article according to the embodiments of FIG. 6A.

FIG. 6C is an exploded cross-sectional elevation view according to the embodiments of FIG. 6A and taken at A-A of FIG. 6A.

FIG. 7A is a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 7B is a side elevation view of a component of a footwear article according to the embodiments of FIG. 7A.

FIG. 7C is an exploded cross-sectional elevation view of a component of a footwear article according to the embodiments of FIG. 7A taken at B-B of FIG. 7A, and related assembly method of a portion of a footwear article.

FIG. 7D is an exploded cross-sectional elevation view according to the embodiments of FIG. 7A and taken at B-B of FIG. 7A and related assembly method of a portion of a footwear article.

FIG. 8A is an exploded perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 8B is an exploded side elevation view of the component of a footwear article according to the embodiments of FIG. 8A.

FIG. 9 is a partially exploded elevation view of a footwear article according to embodiments of the present disclosure.

FIG. 10A is a perspective view of a component of a footwear system according to embodiments of the present disclosure.

FIG. 10B is a perspective view of a component of a footwear system according to the embodiments of FIG. 10A.

FIG. 10C is a perspective view of a component of a footwear system according to the embodiments of FIG. 10A.

FIG. 11 is an exploded perspective view of packaging and accessories for a footwear article according to embodiments of the present disclosure.

FIG. 12 is an exploded perspective view of a footwear article according to embodiments of the present disclosure.

FIG. 13 is an exploded perspective view of a footwear article according to embodiments of the present disclosure.

FIG. 14A is a cross-sectional elevation view of a footwear article according to embodiments of the present disclosure.

FIG. 14B is a cross-sectional elevation view of the footwear article of the embodiments of FIG. 14A and taken at line C-C of FIG. 14A.

FIG. 14C is a cross-sectional elevation view of the footwear article of the embodiments of FIG. 14A and taken at line D-D of FIG. 14A.

FIG. 14D is a cross-sectional elevation view of the footwear article of the embodiments of FIG. 14A and taken at line E-E of FIG. 14A.

FIG. 15A provides a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 15B provides a side elevation view of a component of a footwear article according to the embodiments of FIG. 15A.

FIG. 15C provides a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 15D provides an elevation view of a component of a footwear article according to the embodiments of FIG. 15C.

FIG. 16A is a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 16B is an elevation view of a component of a footwear article according to the embodiments of FIG. 16A.

FIG. 16C is an exploded cross-sectional elevation view of a component of a footwear article according to the embodiments of FIG. 16A taken at F-F of FIG. 16A, and related assembly method of a portion of a footwear article.

FIG. 17A is a plan view of components of a footwear article according to embodiments of the present disclosure.

FIG. 17B is a plan view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 18A is a plan view of components of a footwear article according to embodiments of the present disclosure.

FIG. 18B is a plan view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 19A is a perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 19B is an exploded cross-sectional elevation view of a component of a footwear article according to the embodiments of FIG. 19A, taken at line G-G of FIG. 19A, and related assembly method of a portion of a footwear article.

FIG. 20A is an exploded perspective view of a component of a footwear article according to embodiments of the present disclosure.

FIG. 20B is an expanded perspective view of a component of a footwear article according to the embodiments of FIG. 20A.

FIG. 20C is a cross-sectional elevation view of a component of a footwear article according to the embodiments of FIG. 20A, taken at line H-H of FIG. 20A.

FIG. 21A is a top plan view of a stack of material for a component of a footwear article according to embodiments of the present disclosure.

FIG. 21B is a top plan view for a component of a footwear article according to the embodiments of FIG. 21A, cut from the stack of material of FIG. 21A.

DETAILED DESCRIPTION

FIGS. 1A-21B generally illustrate a footwear article, according to embodiments of the present disclosure. The footwear article is configured to be biodegradable. The footwear article 1 is configured to conform to a user, either based on measurements and form-fitting to a particular user, or based on a particular percentage or percentile of anthropometric data for a subset of users (e.g., ranging between the 5th and 95th percentile). The footwear article is configured to provide a desired degree of rigidity and/or flexibility at select locations within the footwear article. For example, where the footwear article 1 is configured for use for cycling, the footwear article is contemplated as being sufficiently rigid at a first location to promote power transmission to a pedal (e.g., either separated from the footwear article or coupled to the footwear article via a cleat of a clipless pedal system), and be sufficiently flexible at a second location to allow a user to walk when not on the bicycle.

FIGS. 1A-1B are perspective and elevation views of an upper 2 for an article 1 of footwear according to embodiments of the present disclosure. As shown, the upper 2 includes a portion of a shoe or footwear article 1 that is intended to surround the sides and upper portion of a foot. The upper 2 includes an internal volume generally defined by sidewalls 4, a tongue 6, a toe box 8 and a heel portion 10. The upper 2 of FIGS. 1A-1B is depicted as including apertures or holes 12 for receiving and threading a shoelace. In preferred embodiments, shoelaces and related structure are contemplated for use with shoes to allow for the provision of sustainable, environmentally friendly, and biodegradable laces to secure the shoe. It will be recognized, however, that footwear articles of the present disclosure are not limited to laces. For example, the footwear articles of the present disclosure is contemplated as including various fasteners such as but not limited to straps and wire fasteners. Where the footwear articles include straps, wire fasteners, and the like, the straps, wire fasteners, and the like are contemplated as comprising sustainable, environmentally friendly, and/or biodegradable materials.

In preferred embodiments, footwear uppers 2 of the present disclosure include one or more knitted biodegradable material or materials including, for example, bamboo fiber(s) (e.g., white bamboo fiber or original bamboo fiber), coffee bean fiber, soybean fiber, aloe vera fiber, corn fiber (e.g., antibacterial and anti-mite corn fiber), cotton, silk, wool, recycled yarn, lyocell fiber, lyocell fiber blended with wool or recycled yarn, tea polyphenol fibers, chitin fiber, fibroin fiber, and/or hemp fiber. In some embodiments, the upper 2 is completely devoid of synthetic materials. Some structural integrity is provided by the shoe upper 2, but the shoe upper 2 and material selection thereof is largely based on user-comfort while utilizing biodegradable materials.

In various embodiments, footwear articles including uppers 2 are provided with artwork and detail. Printing and artwork for shoe uppers and other components of the present disclosure utilize soy-based ink(s), milk-based paint(s), laser etching, branding, embossing, and/or foil transfer processes. These methods and resulting detail(s) maintain the overall biodegradability of the footwear article 1 and provide means for decorating or detailing the footwear article 1 without introducing synthetic, plastic, or petroleum-based materials.

FIG. 2 illustrates a footbed 20 of embodiments of the present disclosure and a method of forming the same. The footbed 20 is configured to fit within and/or be partially surrounded by an upper 2. As shown, a top sheet 22 is provided. The top sheet is laminated to a base 24 to form the footbed 20. Preferably, the top sheet 22 includes greater structural strength and/or stiffness than the base 24. It is contemplated that the top sheet 22 includes one or more of cork, knitted fabric, bamboo fiber (e.g., white bamboo fiber or original bamboo fiber), coffee bean fiber, soybean fiber, aloe vera fiber, corn fiber (e.g., antibacterial and anti-mite corn fiber), cotton, silk, wool, recycled yarn, lyocell fiber, lyocell fiber blended with wool or recycled yarn, tea polyphenol fibers, chitin fiber, fibroin fiber, and/or hemp fiber. The base 24 is contemplated as including at least one of cork, wool, BLOOM™, ORTHOLITE™, WASCOFFEE™, or similar material. Printing is contemplated as being provided on the footbed 20 by at least one of soy-based inks, milk-based paints, laser etching, branding, embossing, and foil transfer.

FIG. 3A is a perspective view of a heel counter 30 that is operable to accommodate the heel of a foot of a user, according to embodiments of the present disclosure. FIG. 4A is a perspective view of a heel counter 40 that is operable to accommodate the heel of a foot of a user, according to embodiments of the present disclosure.

In some embodiments, the heel counter 30 and/or the heel counter 40 is configured to fit at least partially within the upper 2. In these embodiments, the heel counter 30 and/or the heel counter 40 are at least partially covered by a fabric or other material to prevent injury to the user (e.g., through rubbing, chafing, cutting, and the like). Also in these embodiments, it is noted the heel counter 30 and/or the heel counter 40 are, alternatively or in addition, at least partially covered by and/or received by the footbed 20. In other embodiments, the heel counter 30 and/or the heel counter 40 is configured to fit outside of and at least partially surround the upper 2. In general, any heel counter of the present disclosure are configured to fit within the upper 2 or be configured to fit outside of and at least partially surround the upper 2 without departing from the scope of the present disclosure.

Referring now to FIGS. 3A and 3B, the heel counter 30 includes a convex upper heel structure 32 and a locking feature 34 extending downwardly therefrom that is operable to project or extend into a footwear article. The locking feature 34 includes an open U-shaped element with a void 36 provided therein. The locking feature 34 is contemplated as extending into or otherwise attached to a lasting board of the present disclosure, and in addition further extend into or otherwise attached to additional or alternative footwear article features. FIG. 3B is a side elevation view of the heel counter 30 of the embodiments of FIG. 3A.

Referring now to FIGS. 4A and 4B, the heel counter 40 includes a convex upper heel structure 42 and a locking feature 44 extending downwardly therefrom that is operable to project or extend into a footwear article. The locking feature 44 includes a U-shaped element with a bottom 46 provided therein. The locking feature 44 is contemplated as extending into a void provided in a footbed of the present disclosure and in addition further extend into additional or alternative footwear article features. FIG. 4B is a side elevation view of the heel counter 40 of the embodiments of FIG. 4A. As shown in FIG. 4B, the heel counter 40 is contemplated as being at least partially embedded in or otherwise attached to a lasting board 48. The heel counter 40 and the lasting board 48 are provided on and substantially flush with an outer shell or plate 49.

FIG. 5A is an exploded view of layers for forming a heel counter or portion thereof, according to embodiments of the present disclosure. As shown, a laminated micro-veneer is provided including a plurality of layers. The layers 50, 52, 54, 56, 58 are stacked and pressed together to create a structure. In preferred embodiments, the micro-veneer layers include wood layers with a specific fiber direction. A “lay-up” is provided that preferably includes alternating the directions of the grain in each layer. The plurality of grain directions and layering of the same provides enhanced structural integrity for the resulting structure. Additionally, the layers are shown as rectangular shapes in FIG. 5A but are contemplated as being formed and pressed in various shapes including, for example, a tub-shaped heel counter shape (see FIG. 5B, for example). Ribs (not shown in FIGS. 5A and 5B) are contemplated as being provided to increase strength.

FIG. 5C is an exploded view of layers for forming a laminated component according to another embodiment of the present disclosure. As shown, a plurality of wood layers 50, 52, 56, 58 are provided and at least one metal layer 55 is provided. The metal sheet or layer 55 is depicted as including a middle or central layer in FIG. 5C, but one or more metal layers could be provided in various different positions within a laminated component. Additionally, the layers are shown as rectangular shapes in FIG. 5C but are contemplated as being formed and pressed in various shapes including, for example, a tub-shaped heel counter shape (see FIG. 5D, for example). Ribs (not shown in FIGS. 5C and 5D) are contemplated as being provided to increase strength.

Embodiments and structures of the present disclosure are well suited for forming cycling shoes from sustainable materials while still achieving a desired or required amount of stiffness and support. It will be recognized, however, that methods, systems, and structures of the present disclosure are not limited to use with cycling shoes or specific materials. While certain preferred embodiments are shown and described herein, inventive aspects and structures of the present disclosure are contemplated as being used in various different footwear articles.

FIG. 6A is an exploded perspective view of a lasting board 60 according to embodiments of the present disclosure. As shown, the lasting board 60 includes first and second layers 62, 64. The first layer 62 is contemplated as including a laminated or non-laminated wood, wood core, or wood veneer layer preferably including a light-weight wood (e.g., balsa wood or cork) that nests or connects with a second layer 64. The second layer 64 is contemplated as including a stamped metal layer (e.g., stamped titanium or aluminum, an element or pure metal (e.g., complementary, or substantially pure), a metal alloy, and the like). In some embodiments, both layers 62, 64 including wood including, for example, laminated or non-laminated wood, wood core, or wood veneer layers.

As shown in FIG. 6A, at least the first layer 62 includes an aperture or recess 66 for receiving a heel counter (FIGS. 4A-4B, for example). In some embodiments, the first and second layers also include apertures 67 for receiving fasteners for mounting a cycling cleat. For example, the apertures 67 is contemplated as including female threaded apertures. The lasting board or plate 60 preferably includes a plurality of holes or apertures 69 distributed about a perimeter of the lasting board 60. The apertures 69 are provided for stitching or otherwise securing an upper to the lasting board 60.

FIG. 6B is a side elevation view of a formed lasting board 60 including a first layer 62 secured to a second layer 64. FIG. 6C provides cross-sectional views of the lasting board 60 taken at A-A of FIG. 6A. As shown, the lasting board 60 includes an asymmetry wherein an arch portion of the footbed extends upwardly. The lower layer or plate 64 includes a stamped metal with one more protrusions to increase contact area with the first layer or plate 62.

In some embodiments, the lasting board 60 of FIGS. 6A-6C comprises ridges or support features 65 to provide structure and rigidity to the device, as well as provide enhanced surface area for securing the first layer 62 and the lower layer or plate 64. As shown, three divergent ridges 65 are provided, but alternative numbers, spacing, and shapes of ridges are contemplated without departing from the scope of the present disclosure.

FIGS. 7A-7B are perspective and side elevation views of an outer shell or plate 70 according to embodiments of the present disclosure. As shown, the outer shell 70 includes a rigid or semi-rigid member to provide strength and stability to the formed footwear article or shoe. The rigid or semi-rigid member covers the stitching and underlying components, and generally provides shape to the shoe. An aperture 72 is provided to allow access to internal components of certain embodiments including, for example, threaded apertures for receiving and secured a cleat, or other cleat hardware for receiving a clip-in cleat. The outer shell 70 preferably includes a laminated structure (see FIG. 5, for example, and otherwise as described throughout the disclosure) wherein a plurality of layers are stacked and pressed together to create the outer structure of the shoe. In some embodiments, the outer shell 70 is secured to the lasting board 60 by at least one of pressure or press-fitting and adhesive(s). In various embodiments, the outer shell 70 includes a plurality of wood layers (see FIG. 5A, for example). It is also contemplated that the outer shell 70 is formed using at least one metal layer in combination with wood layers (see FIG. 5C, for example).

FIG. 7C provides a first lay-up option according to a first embodiment and FIG. 7D provides a second lay-up option according to a second embodiment (Option 1 and Option 2), with corresponding cross-sectional elevation views taken at B-B of FIG. 7A. As shown, a plurality of wood layers with differing grain directions are laminated to form an outer shell 70.

In the embodiment of FIG. 7C, a first layer is an outer or visible layer with grain direction a. The second layer includes a grain direction b that is a cross grain from the first layer. The third layer includes a grain direction c that is a cross grain from the second layer. The fourth layer includes a grain direction d that is a cross grain from the third layer. The fifth layer is an inside layer with a grain direction e that is a cross grain from the fourth layer.

In the embodiment of FIG. 7D, at least one metal layer is also provided to increase stiffness of the outer shell 70. The first layer is an outer or visible layer with grain direction a. The second layer includes a grain direction b that is a cross grain from the first layer. The third layer includes a metal. The fourth layer includes a grain direction c that is a cross grain from the second layer. The fifth layer is an inside layer with a grain direction d that is a cross grain from the fourth layer.

FIGS. 8A-8B are perspective and elevation views of an assembly process of the present disclosure, respectively. As shown, a heel counter 40 is provided and includes a locking element 44. The heel counter 40 is operable to connect to a lasting board 60. Specifically, the locking element 44 is operable to extend into an aperture 66 of the lasting board 60. An outer shell 70 is provided, and the lasting board 60 and heel counter 40 are secured to the outer shell 70. For example, the locking element 44 may pass through the aperture 66 of the lasting board 60 and engage the outer shell 70. By way of another example, the locking element 44 may engage the aperture 66, while the opposite side of the aperture 66 and/or another portion of the lasting board 600 may be capable of engaging with the outer shell 70 (e.g., via interfacing components, adhesives, stitching, and the like).

FIG. 9 is a partially-exploded side elevation view of components of a footwear article 1 and formation step according to embodiments of the present disclosure. As shown, an upper 2 is provided. A heel counter or cup 40 is provided and secured around a portion of the upper 2. In some embodiments, the upper 2 is Strobel stitched to a lasting board 60 according to Option A. In other embodiments, the upper 2 is lasted and glued to the lasting board 60 according to Option B. The heel counter or cup 40 extends into the lasting board 60 (see FIG. 8A, for example) and the lasting board 60 is secured to the outer shell or plate 70 (e.g., either separately from the heel counter or cup 40, or alternatively with the assistance of the heel counter or cup 40. In other embodiments, the heel counter or cup 40 fits within the upper 2. In these embodiments, the heel counter or cup 40 is attached to the lasting board 60 and the outer shell 70 via Option A or Option B. In addition, or in the alternative, the heel counter or cup 40 passes through the upper 2 to engage the lasting board 60 and/or the upper shell 70.

FIGS. 10A-10C provide various views of a foot form device 80 according to embodiments of the present disclosure. In various embodiments, the foot form device 80 includes a molded pulp member for giving shape to the footwear article or shoe 1 for displaying and packaging purposes. The foot form device 80 is preferably formed from and/or includes pulp, recycled paper, recycled paper with plant seeds, and similarly biodegradable and/or compostable materials. In various embodiments, it is contemplated that the device 80 further includes a cleat-fitting and alignment device 90 to assist a user in transferring cleats from one pair of shoes to another, for example. In such embodiments, it is contemplated that the cleat position from a first pair of shoes can be imprinted on the foot form device 80, and the foot form device 80 is then used as a template or drawing tool to mark or otherwise indicate the preferred cleat position for a second (e.g., new) pair of shoes.

FIG. 11 is a perspective view of a packaging system 100 for footwear articles according to embodiments of the present disclosure. As shown, a box 102, packaging paper 104, and cleat measurement tool 106 are provided. The box 102, paper 104, and cleat measurement tool 106 are preferably formed of a biodegradable material and wherein the entirety of a box 102 and contents (including footwear articles as shown and described herein) are biodegradable and/or compostable. In some embodiments, the cleat measurement tool 106 assists a user in installing cleats or transferring cleats from one pair of shoes to another, for example. In such embodiments, it is contemplated that the cleat position from a first pair of shoes can be imprinted or marked on the cleat measurement tool 106, and the cleat measurement tool 106 is then used as a template or drawing tool to mark or otherwise indicate the preferred cleat position for a second (e.g., new) pair of shoes. Printing and artwork for the box 102 and related articles is preferably achieved by at least one of soy-based inks, milk-based paints, laser etching, branding, embossing, and foil transfer.

FIG. 12 is an exploded perspective view of a footwear article 110 according to embodiments of the present disclosure. Unless otherwise noted, the footwear article 110 has features that are the same as, or similar to, other embodiments of footwear articles described throughout the present disclosure and operates in the same or similar manner. In this regard, embodiments directed to the footwear article 1 should be interpreted as being applicable to the footwear article 110, and vice versa, unless otherwise noted.

As shown, the article 110 includes an outsole 112 (or outer layer or shell). The outsole 112 is contemplated as including but is not limited to an outsole made of or molded from natural and/or recycled rubber. A projection 114 is provided in a portion of the outsole 112 to accommodate additional components of the present disclosure as will be shown and described herein. An arch support member 116 is provided in the embodiments of FIG. 12 to provide support and comfort to a user's arch. The arch support 116 is contemplated as including at least one of felt, cork, rubber, and pulp. A lasting board 118 a is further provided. The lasting board or plate 118 a is contemplated as including a structural element that is operable to communicate with at least one of the outsole 112, the arch support 116, a heel cushion 119 and a heel counter 120. As shown in FIG. 12, the lasting board 118 a includes a heel portion 122, an arch portion 124, and a distal portion 126. The heel portion 122 is contemplated as including a substantially planar portion that is operable to contact and/or be secured to the outsole 112. In some embodiments, some concavity or curvature is provided in the heel portion 122. The arch portion 124 of the lasting board 118 a includes a convex structure that is operable to accommodate a user's arch on an upper side of the lasting board 118 a and the arch support 116 on a lower side of the lasting board 118 a. In some embodiments, and as shown in FIG. 12, flanges 128 are provided on lateral sides of the arch portion 124.

The embodiments of FIG. 12 include a lasting board 118 a having at least one notch 130 to provide for flexibility in the fore or distal part of the article. As shown in FIG. 12, the lasting board 118 a includes a plurality of notches 130 a, 130 b, 130 c, 130 d, 130 e or slots to allow for some flexure in an otherwise rigid plate element. The flexure or bending provided by the slots allows for off-bike activities including, for example, walking.

FIG. 13 is an exploded perspective view of a footwear article 140 according to embodiments of the present disclosure. Unless otherwise noted, the footwear article 140 has features that are the same as, or similar to, other embodiments of footwear articles described throughout the present disclosure and operates in the same or similar manner. In this regard, embodiments directed to the footwear article 1 and/or 110 should be interpreted as being applicable to the footwear article 140, and vice versa, unless otherwise noted.

As shown, the article 140 includes various elements shown and described with respect to FIG. 13 including, for example, an outsole 112 with a projection 114, an arch support member 116, a lasting board 118 b, a heel cushion 119 and a heel counter 120. The outsole 112 is contemplated as including but is not limited to an outsole made of or molded from natural and/or recycled rubber. A projection 114 is provided in a portion of the outsole 112 to accommodate additional components of the present disclosure as will be shown and described herein. An arch support member 116 is provided in the embodiments of FIG. 13 to provide support and comfort to a user's arch. The arch support 116 is contemplated as including at least one of felt, cork, rubber, and pulp. A lasting board 118 b is further provided. The lasting board or plate 118 b is contemplated as including a structural element that is operable to communicate with at least one of the outsole 112, the arch support 116, a heel cushion 118 and a heel counter 120. As shown in FIG. 13, the lasting board 118 b includes a heel portion 122, an arch portion 124, and a distal portion 126. The heel portion 122 is contemplated as including a substantially planar portion that is operable to contact and/or be secured to the outsole 112. In some embodiments, some concavity or curvature is provided in the heel portion 122. The arch portion 124 of the lasting board 118 b includes a convex structure that is operable to accommodate a user's arch on an upper side of the lasting board 118 b and the arch support 116 on a lower side of the lasting board 118. In some embodiments, and as shown in FIG. 13, flanges 128 are provided on lateral sides of the arch portion 124.

The embodiments of FIG. 13 include a lasting board 118 b having at least one notch 130 to provide for flexibility in the fore or distal part of the article. As shown in FIG. 13, the lasting board 118 b includes a plurality of notches 130 a, 130 b or slots to allow for some flexure in an otherwise rigid plate element. The flexure or bending provided by the slots allows for off-bike walking.

Additionally, the lasting board 118 b of FIG. 13 includes a cut-away distal portion 126 wherein a support 148 is provided on the inner portion of the lasting board 118 b to provide support and comfort along an interior portion of a foot. An exterior lateral portion of the lasting board 118 b includes a cut-away or void 150 (e.g., at the distal portion 126) to allow for additional flexure in the article and the lasting board 118 b to facilitate walking. For purposes of the present disclosure, “inner portion” is described as being on the inside of a foot, or the portion of the foot proximate to an opposite foot.

FIG. 14A is a cross-sectional side view of a footwear article 142 and its various components according to embodiments of the present disclosure. Unless otherwise noted, the footwear article 142 has features that are the same as, or similar to, other embodiments of footwear articles described throughout the present disclosure and operates in the same or similar manner. In this regard, embodiments directed to the footwear articles 1, 110, and/or 140 should be interpreted as being applicable to the footwear article 142, and vice versa, unless otherwise noted.

As shown in FIG. 14A, an outsole 112 is provided. A lasting board 118 is provided and extends over an arch support 124. A heel cushion 119 is provided and a heel counter 120 is provided. As will be recognized by one of ordinary skill in the art, various known cycling shoes provide for stiff or rigid soles that are designed to optimized power transfer between a rider and a bicycle. Such known devices generally fail to provide a shoe that is suitable for cycling as well as walking when one transitions from riding to other activities. Embodiments of the present disclosure including but not limited to that shown in FIG. 14A provide for a footwear article that are suitable for cycling and various off-bike activities. The forefoot portion of the shoe and lasting board 118 of FIG. 14A provide for flexion or bending about a transverse axis (see 125 in FIG. 12) of the shoe.

FIG. 14B is a cross-sectional view of components of the footwear article 142 according to the embodiments of FIG. 14A and taken at line C-C of FIG. 14A. As shown, the outsole 112 and lasting board 118 are provided in a layered arrangement. The lasting board 118 of the depicted embodiment and its generally flat or shallow shape at line C-C provide for flexibility and comfort when walking (while off the bike, for example).

FIG. 14C is a cross-sectional view of components of a footwear article 142 according to the embodiments of FIG. 14A and taken at line D-D of FIG. 14A. The outsole 112, lasting board 118 and arch portion 124 (with arch support member 116) are shown relative to one another. At the mid-foot section of FIG. 14C, the lasting board 118 of the depicted embodiment includes flanges or has a “bath tub” shape to support a user's foot and provide strength and rigidity to the assembled device over a pedal where stiffness is preferred.

FIG. 14D is a cross-sectional view of components of the footwear article 142 according to the embodiments of FIG. 14A and taken at line E-E of FIG. 14A. The outsole 112, lasting board 118, heel cushion 119, and heel counter 120 are shown relative to one another. The heel portion (section E-E) is contemplated as including a substantially flat or shallow portion to provide flexibility to the lasting board 118 and comfort when walking (while off the bike, for example). In alternative embodiments, however, it is contemplated that the heel portion is provided with a curvature or with flanges to enhance stiffness in this region.

The heel counter 120 of FIGS. 14A-14D is contemplated as including substantially the same construction as that shown and described with respect to FIGS. 3A-5D and that discussion is hereby incorporated by reference in its entirety. The heel counter 120 provides torsional stability, foot stability, and support to an assembled footwear article.

FIGS. 15A and 15B provides perspective and side elevation views of a heel counter 120 a according to embodiments of the present disclosure. As shown, the heel counter 120 a includes an open bottom portion 146. The heel counter 120 a connects to a lasting board 118 and provides stability and stiffness to an assembled footwear article. For example, the heel counter 120 a is capable of locking into the lasting board 118.

FIGS. 15C and 15D provides perspective and side elevation views of a heel counter 120 b according to embodiments of the present disclosure. As shown, the heel counter 120 b includes a closed bottom portion 152. The heel counter 120 b connects to a lasting board 118 and provides stability and stiffness to an assembled footwear article. As shown in FIG. 15D, the heel counter 120 b is sandwiched between a heel portion of the lasting board 118 and the lasting board 118 and a heel cushion 119. Alternative arrangement and layering, however, are contemplated. In some embodiments, for example, it is contemplated that a portion of the heel counter 120 is layered between the outsole and the lasting board. In some embodiments, the outsole conforms to and is secured to at least a portion of the heel counter 120 b.

FIGS. 16A-16C provide various views and details of a lasting board 118 according to embodiments of the present disclosure. As shown in FIG. 16A, a lasting board is provided that includes a layered or laminated structure and which preferably includes sustainable materials including but not limited to biodegradable and/or recyclable materials. The lasting board 118 includes a heel portion 122, an arch portion 124, and flanges 154 to provide support. The lasting board 118 preferably includes a plurality of layers including, for example, a wood layer 156 (e.g., a top lightweight wood layer), a fabric layer 157 (e.g., allowing for flexibility in the forefoot of the plate), a second wood layer 158 (e.g., a bottom layer adding strength), and printing or decoration (e.g., applied with soy based inks, milk based paint, laser etching, branding or burning, embossing (pressing during molding), or foil transfer) on one or more of the layers A-C. FIG. 16B shows the lasting board 118 in an elevation view.

FIG. 16C provides additional details on the construction and components of the lasting board 118. As shown in FIG. 16C, the lasting board 118 includes a plurality of layers 156, 157, 158. A first layer 156 is contemplated as including a wood veneer layer. The wood veneer layer 156 is contemplated as including a plurality of laminated wood layers having wood grain provided in different directions. A second layer 157 is provided that includes a flexible material including, for example, a fabric. A third layer 158 is provided that is contemplated as including a second wood veneer layer having a plurality of laminated wood layers with grain directions provided in different orientations and as shown in FIG. 16C. First layer 156, second layer 157, and third layer 158 are contemplated as being secured together to form a layered lasting board 118. The lasting board 118 is the backbone. Added sections or layers within the lasting board 118 allows for the lasting board 118 to be rigid in some areas and flexible in others, which is important because the lasting board 118 is intended for flexibility when walking but also to be rigid while pushing down on a pedal for cycling.

FIGS. 17A-17B provides plan views of a plurality of different lasting boards 118 (1, 2, 3, 4) according to embodiments of the present disclosure. The lasting boards of FIG. 17A-17B are contemplated as including lasting boards for footwear articles that are not intended to receive a cleat for a clipless cycling pedal system. The embodiments of FIG. 17A-17B are contemplated as being suitable for use with flat pedal systems (for example) as well as various non-cycling related activities including but not limited to walking. The lasting boards are contemplated as including at least one and preferably a plurality of slots 130 for allowing the lasting board to flex or bend while walking (while off the bike, for example). The lasting boards are further contemplated as including various cut-outs and voids to allow flexure of the system. FIG. 17B depicts a lasting board 118 (e.g., 4) according to embodiments of the present disclosure. As shown, the lasting board 118 includes support 160 along the majority of an inner portion of the lasting board 118. A void space 162 within or proximate to the inner portion is provided to reduce overall stiffness and allow for flexure and comfort while engaging in non-cycling activities.

FIGS. 18A-18B provide plan views of a plurality of different lasting boards 118 (1 a, 2 a, 3 a, 4 a) according to embodiments of the present disclosure. The lasting boards of FIG. 18A-18B are contemplated as including lasting boards for footwear articles that are intended to receive a cleat for a clipless cycling pedal system, as well as various non-cycling related activities including but not limited to walking. The lasting boards are contemplated as including at least one and preferably a plurality of slots 130 for allowing the lasting board to flex or bend while walking (while off the bike, for example). The lasting boards are further contemplated as including various cut-outs and voids to allow flexure of the system. As shown, the lasting boards 118 of the embodiments of FIG. 18A-18B include a cut-out or recess 164 for receiving additional components including, for example, cleat for cycling pedals. FIGS. 18A-18B generally illustrate and contemplate the ability to accommodate a SHIMANO SPD™ cleat. It will be recognized, however, that the present disclosure and the embodiments shown and discussed herein are not limited to any particular pedal or cleat system.

FIG. 19A is a perspective view of a lasting board 118 according to embodiments of the present disclosure, with cross section view A-A. For example, FIG. 19A illustrates the embodiment of the lasting board 118 of FIG. 18B. FIG. 19B is an exploded cross-sectional view of the lasting board 118 taken at the indicated cross section line G-G of FIG. 19A, with top layer 156, middle layer or fabric/flexible layer 157, and bottom layer 158. The lasting board 118 is contemplated as including a plurality of laminated layers 156, 157, 158 with void spaces for receiving cleat hardware 166 including (for example) bolts and female threaded apertures for selectively securing a cleat to the article of footwear.

FIG. 20A is an exploded perspective view of a lasting board 118, with cross section line H-H. In FIG. 20A, the lasting board 118 includes six layers, with rigid or semi-rigid layers 170, 172, 174, 176 positioned between fabric/flexible layers 168 and 178. For example, in some embodiments the layers 168 and/or 178 are fabricated from a silk or woven fabric, while one or more of the layers 170, 172, 174, 176 are fabricated from a wood layer (e.g., wood veneer). FIG. 20B is an expanded view of the layers 168, 170, 172, 174, 176, 178 of the lasting board 118 in FIG. 20A. FIG. 20C is a cross section view at line H-H of the lasting board 118 of FIG. 20A.

In one example embodiment, the layers 170, 172, 174, 176 is laminated micro-veneer layers, which are stacked and pressed together to create a structure. In preferred embodiments, the micro-veneer layers include wood layers with a specific fiber direction. A “lay-up” is provided that preferably includes alternating the directions of the grain in each layer. The plurality of grain directions and layering of the same provides enhanced structural integrity for the resulting structure. Additionally, the layers are shown as footpad shapes in FIG. 20A-20C but are contemplated as being formed and pressed in various shapes including, for example, a tub-shaped heel counter shape. Ribs (not shown in FIGS. 20A and 20C) are contemplated as being provided to increase strength.

As illustrated in FIG. 20A-20C, a first subset of layers is different in dimension than a second subset of layers. For example, at least one of the layers 170, 172, 174, 176 is contemplated as comprising a difference in dimension (e.g., shorter, and the like) compared to the other layers. For instance, the lasting board 118 is contemplated as comprising layers 168, 170, 172, 174, and 178 which are dimensioned to provide support 160 along an inner portion proximate to the toe region, and a void 162 for the remainder of the toe region. In addition, the lasting board 118 is contemplated as comprising a layer 176 which provides no support 160 to the toe region, such that the layer 176 is truncated or shorter in total length than the layers 168, 170, 172, 174, and 178. This difference in dimension may allow for focusing of rigidity, flexibility, and/or application of force within the lasting board 118, while reducing a thickness of the lasting board 118 at the location of the different dimensions. For example, shorting the layer 176 as illustrated in FIGS. 20A-20C proximate to the toe region of the lasting board 118 reduces the thickness in the toe region, and allow for a more flexible toe region, while retaining a desired stiffness in the ball, arch, and heel regions of the lasting board 118.

Where a layer 176 is truncated or shorter than other layers, the layer 176 includes an edge 173.

In one example embodiment, the edge 173 is dimensioned to be constant in distance from the heel region, relative to a longitudinal axis through the lasting board 118, where the longitudinal axis is defined along a central or bisecting axis from the heel region to the toe region of the lasting board 118. For example, the layer 176 may include a lateral edge 173 that is perpendicular or substantially perpendicular to the longitudinal axis through the lasting board 118. By way of another example, the layer 176 may include an edge 173 that is contoured to conform to a ball of user's foot. For example, contouring to conform to the user's foot may set the lateral edge 173 at a non-perpendicular angle to the longitudinal axis through the lasting board 118. It is contemplated this configuration provides flexibility in the toe region of the user's foot such as when walking due to the layer 176 being absent, while providing additional rigidity to the remainder of the lasting board 118 (e.g., in the region of the sole and the heel) due to the additional layer 176 being present.

In another example embodiment, the edge 173 includes a middle point 175 proximate to the toe region which is greater in distance from the heel region than the distances of points 177 along the outer edges 179 of the lasting board 118 from the heel region, relative to the longitudinal axis through the lasting board 118. For example, the middle point 175 may be set on the longitudinal axis of the lasting board 118 and proximate to the toe region. By way of another example, the middle point 175 may be offset from the longitudinal axis of the lasting board 118 (e.g., between the longitudinal axis and the support 160 of the lasting board 118) and proximate to the toe region. It is contemplated this configuration provides increased rigidity along a spine of the lasting board 118, as the middle point 175 may be increased in distance from the heel region as compared to where the edge 173 is constant in distance along its lateral length relative to the heel region. In addition, it is noted this configuration also allows for increased flexibility in the toe region (e.g., including proximate to the support 160), as the points 177 on the outer edges 179 of the lasting board 118 may be decreased in distance from the heel region as compared to where the edge 173 is constant in distance along its lateral length relative to the heel region.

It is noted the above example embodiments are not limited to the layer 176, and that any layer or layers of the lasting board 118 may be truncated or shorter without departing from the scope of the present disclosure.

It is noted the flexible layer 178 may contact the layer 176 along a first portion of the lasting board 118 and may contact the layer 174 along a second portion of the lasting board 118, due to the difference in dimension (e.g., length, and the like) of the layer 176. In addition, it is noted the fabric layers 168 and 178 contemplated as protecting the inner wood support layers 170, 172, 174, 176, while also increasing comfort of the lasting board 118.

Although FIGS. 20A-20C include layers 168, 170, 172, 174, 176, 178, it is contemplated that the lasting board 118 in FIGS. 20A-20C includes more or fewer layers than those depicted and described, without departing from the present disclosure.

As illustrated in at least FIGS. 20A-20C, the layers 168, 170, 172, 174, 176, 178 is contemplated as being pre-cut and then laminated or otherwise adhered together. In an alternative embodiment, FIG. 21A illustrates a laminated stack 180 of material and FIG. 21B illustrates a lasting board 118 cut from the laminated stack 180. In this embodiment, layers of a lasting board 118 are stacked, laminated, or otherwise adhered, and then cut to the desired dimensions. This embodiment reduces the possibility of a miscut between layers, such that the layers of the lasting board 118 do not align when stacked together for lamination. It is noted this arrangement still allows for the focusing of rigidity, flexibility, and/or general application of force within the lasting board 118 as any layer with different dimensions is capable of being formed prior to arrangement in the stack, as illustrated in FIGS. 21A and 21B with the difference is color variations representing different dimensioned layers.

It should be understood the lasting board in FIGS. 20A-21B are capable of including a cut-out or recess 164 to receive cleat hardware 166 as illustrated in FIGS. 18A-19B, without departing from the scope of the present disclosure.

Various embodiments of the present disclosure including but not limited to those shown in FIGS. 1A-21B provide footwear articles and related features. The articles and related features, components, etc. are contemplated as including one or more sustainable materials such as compostable, biodegradable, recycled, recyclable, and reusable materials. In some embodiments, for example, articles are provided that are devoid of material that is not accepted by a commercial composting facility.

Although aspects of the present disclosure are directed to a footwear article usable with cycling cleats, it is noted the various features and embodiments as described throughout the present disclosure are not limited only to use with the cycling cleats. For example, various features and embodiments as described throughout the present disclosure are contemplated as being applicable to any worn footwear article including, but not limited to, a tennis shoe, a sneaker, a hiking shoe or boot, a climbing shoe or boot, a sports-specific (e.g., baseball, softball, soccer, golf, or the like) shoe, a dress shoe, a sandal, or any other article of footwear without departing from the scope of the present disclosure. Where the footwear article is not a cycling shoe, the lasting board 118 and/or other components of the footwear article may or may not be configured to receive the cycling cleat. For example, the lasting board 118 may or may not include the apertures or other mounting locations for the cycling cleat, as illustrated and described throughout the present disclosure.

Various features and embodiments of a footwear article have been provided herein. It will be recognized, however, that various features are not necessarily specific to certain embodiments and may be provided on any one or more embodiments. The present disclosure and embodiments provided herein are not mutually exclusive and may be combined, substituted, and omitted. The scope of the invention(s) provided herein is thus not limited to any particular embodiment, drawing, or particular arrangement of features.

It is to be understood that the disclosure is not limited to particular methods or systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the following claims.

While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Further, the invention(s) described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. 

What is claimed is:
 1. A footwear article comprising: a lasting board; a heel counter configured to couple to the lasting board by inserting a portion of the heel counter into the lasting board; and a footwear upper comprising a knit fabric, wherein the footwear upper is configured to couple to at least one of the heel counter and the lasting board, wherein at least one of the heel counter and the lasting board comprises a plurality of stacked wood layers and wherein at least two adjacent wood layers comprise non-parallel grain directions.
 2. The footwear article of claim 1, wherein at least one metal or fabric layer is inserted between adjacent wood layers of the plurality of stacked wood layers.
 3. The footwear article of claim 1, wherein at least one of the heel counter and the lasting board comprises at least one fabric layer surrounding the plurality of stacked wood layers.
 4. The footwear article of claim 1, wherein at least an inner portion of the lasting board includes a support positioned in a toe region.
 5. The footwear article of claim 4, wherein the lasting board includes a void positioned proximate to the support in the toe region.
 6. The footwear article of claim 4, wherein the lasting board includes at least one location where a first subset of the plurality of stacked wood layers is differently dimensioned from a second subset of the plurality of stacked wood layers, wherein a thickness of the lasting board is decreased and a flexibility of the lasting board is increased at the location due to the different dimensioning.
 7. The footwear article of claim 6, wherein the first subset of the plurality of stacked wood layers are dimensioned to include the support positioned in the toe region, and wherein the second subset of the plurality of stacked wood layers is differently dimensioned and does not include the support positioned in the toe region.
 8. The footwear article of claim 1, wherein the lasting board includes at least one notch positioned proximate to a toe region, wherein the notch increases flexibility of the lasting board proximate to the toe region.
 9. The footwear article of claim 1, wherein the article is devoid of synthetic and petroleum-based products.
 10. The footwear article of claim 1, wherein the footwear upper, the heel counter, the footbed, and the lasting board of the footwear article is biodegradable and compostable.
 11. The footwear article of claim 1, wherein the article comprises at least one aperture for a cycling cleat.
 12. The footwear article of claim 13, wherein the at least one aperture is a female threaded aperture for receiving a fastener for the cycling cleat.
 13. The footwear article of claim 13, wherein the at least one aperture includes one or more slots for receiving the cycling cleat or cleat hardware configured to couple to the cycling cleat.
 14. A method of forming a footwear article comprising: forming a footwear upper of the footwear article from a knit fabric; forming at least one of a heel counter and a lasting board for the footwear article from a plurality of stacked wood layers by laminating the plurality of stacked wood layers, wherein at least two adjacent wood layers comprise non-parallel grain directions; coupling the heel counter and the lasting board by inserting a portion of the heel counter into the lasting board; and coupling the footwear upper to at least one of the heel counter and the lasting board.
 15. The method of claim 14, wherein the footwear upper, the heel counter, and the lasting board are each formed from one or more of a bamboo fiber, coffee bean fiber, soybean fiber, aloe vera fiber, corn fiber, cotton, silk, wool, recycled yarn, lyocell fiber, lyocell fiber blended with wool or recycled yarn, tea polyphenol fibers, chitin fiber, fibroin fiber, hemp fiber, cork, knitted fabric, wood, wood core, wood veneer, elemental or pure metal, and an alloy metal.
 16. The method of claim 14, further comprising: applying printing to at least one of the footwear upper, the heel counter, and the lasting board include printing, wherein the printing is applied using one or more of a soy-based ink, milk-based paint, laser etching, branding, embossing, and foil transfer.
 17. A system including a footwear article, comprising: a set of footwear articles, each footwear article comprising: a lasting board; a heel counter configured to couple to the lasting board by inserting a portion of the heel counter into the lasting board; and a footwear upper comprising a knit fabric, wherein the footwear upper is configured to couple to at least one of the heel counter and the lasting board, wherein at least one of the heel counter and the lasting board comprises a plurality of stacked wood layers and wherein at least two adjacent wood layers comprise non-parallel grain directions; a foot form device configured to fit within each footwear article of the set of footwear articles; and packaging including paper capable of wrapping around the set of footwear articles.
 18. The system of claim 17, wherein the packaging and the foot form device are each fabricated from one or more of pulp, recycled paper, recycled paper with plant seeds, and wherein at least one of the packaging and the foot form device includes printing applied using one or more of a soy-based ink, milk-based paint, laser etching, branding, embossing, and foil transfer.
 19. The system of claim 17, wherein the foot form device includes a cleat-fitting and alignment device for installing a cycling cleat on a second footwear article of a second set of footwear articles by marking a cleat position from a footwear article of the set of footwear articles on the cleat-fitting and alignment device as a template.
 20. The system of claim 17, wherein the packaging comprises a cleat measurement tool for installing a cycling cleat on a second footwear article of a second set of footwear articles by marking a cleat position from a footwear article of the set of footwear articles on the cleat measurement tool as a template. 